Methods of forming parts using forming tools and flexible ultrasonic transducer arrays

ABSTRACT

A method of forming parts uses a forming tool having a forming surface, and an ultrasonic transducer array on the forming surface.

BACKGROUND

Ultrasonic testing is commonly used in the aircraft industry to validatethe health (e.g., integrity and fitness) of aircraft structures. Thetesting may be performed by scanning an ultrasonic transducer array overa surface of a structure. For large structures, the transducer array maybe scanned with a robotic multi-axis scanning system.

SUMMARY

According to an embodiment herein, an apparatus comprises a forming toolhaving a forming surface, and an ultrasonic transducer array on theforming surface.

According to another embodiment herein, a method comprises placing anuncured ply stack and a flexible ultrasonic transducer array on aforming surface of a forming tool.

According to another embodiment herein, an article comprises a curedfiber reinforced plastic part and a flexible ultrasonic transducer arrayembedded in the cured part.

These features and functions may be achieved independently in variousembodiments or may be combined in other embodiments. Further details ofthe embodiments can be seen with reference to the following descriptionand drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustration of a flexible ultrasonic transducer array.

FIG. 2 is an illustration of an apparatus including a forming tool and aflexible ultrasonic transducer array.

FIGS. 3, 4, 5 and 6 are illustrations of different methods of using aforming tool and a flexible ultrasonic transducer array to fabricate afiber reinforced plastic part.

FIGS. 7 and 8 are illustration of molds and flexible ultrasonictransducer arrays for forming molded parts.

FIG. 9 is an illustration of an apparatus including a heat blanket and aflexible ultrasonic transducer array.

FIG. 10 is an illustration of a composite part with an embedded flexibleultrasonic transducer array.

DETAILED DESCRIPTION

Reference is made to FIG. 1 , which illustrates a flexible ultrasonictransducer array 110. The transducer array 110 includes a plurality oftransducer elements 120 arranged in a pattern. The transducer elements120 are not limited to any particular pattern. In some instances, thepattern may be a grid (e.g., square, rectangular, triangular) of thetransducer elements 120.

The transducer array 120 is not limited to any particular construction.As a first example, a transducer array 120 includes a pattern ofindividual elements 120.

As a second example, the transducer array 110 includes a thin metalfoil, a film of piezoelectric material on the foil, and top electrodeson film. The thin metal foil serves as a substrate and base electrodeand may be flexed. The electrodes may be printed onto a single sheet,which is on the film.

As a third example, the transducer array 110 includes a flexible mat, areceiver layer of piezoelectric material on one side of the flexiblemat, and a transmitter layer of piezoelectric material on an oppositeside of the flexible mat. A plurality of electrodes are on thepiezoelectric material of the receiver layer, and a plurality ofelectrodes are on the piezoelectric material of the transmitter layer.The electrodes on the receiver layer may be perpendicular or angled withrespect to the electrodes on the transmitter layer. Each transducerelement 120 is formed by an overlapping portion of an electrode in thetransmitter layer with an electrode in the receiver layer.

The electrodes are not limited to any particular geometry. Width andthickness may be constant or varying. Geometry may even vary. Forinstance, an electrode may have rectangular portions and hexagonal orcircular portions.

The flexible transducer array 110 may be mounted on a flexible circuitboard. The circuit board may be a made of a dielectric such as Kapton®polyimide film.

As discussed below, the flexible ultrasonic transducer array 110 will besubjected to curing temperatures and pressures. Therefore, thepiezoelectric material is selected to withstand such temperatures andpressures (the temperatures and pressures will, of course, depend uponthe material being cured). Examples of piezoelectric materials that canwithstand temperatures and pressures for curing fiber reinforcedcomposites include, without limitation, calcium oxyborate, langanite,and bismuth titanate.

Reference is made to FIG. 2 , which illustrates an apparatus 210including a tool 220 for forming a part. The tool 220 includes a body222 having a forming surface 224. The forming surface 224 may have anon-planar shape. Examples of tools 220 include, but are not limited to,mandrels, injection molds, resin transfer molds, and press molds.

The apparatus 210 further includes a flexible ultrasonic transducerarray 230 on the forming surface 224. The ultrasonic transducer array230 may cover the entire forming surface 224 or it may partially coverthe forming surface 224. For example, the transducer array 230 may onlycover select areas of interest of the forming surface 224.

As used herein, the term “on the forming surface” may mean directphysical contact with the forming surface. The term “on the formingsurface” may also mean spaced apart from the forming surface, forexample, by a thin layer (e.g., a layer of adhesive) or spaced apart bythe part being fabricated. When on the forming surface 224, theultrasonic transducer array 230 conforms to the shape of the formingsurface 224. The flexibility of the array 230 enables the array toconform to the shape of the forming surface 224.

The flexible transducer array 230 may be secured to the tool 220. Forinstance, the array 230 may be mechanically clamped to the tool 220,adhesively bonded to the tool 220, or vacuum bagged down against thetool 220. In some instances, the flexible transducer array 230 may notbe secured and may instead sit on the tool 220.

The tool 220 may be used to fabricate a part made of a material such asfiber reinforced plastic (“FRP”). An FRP part may be fabricated bylaying up a ply stack on the forming surface 224 of the forming tool220. The ply stack may include one or more plies of fabric. Forinstance, the ply stack may include one or more plies of carbon fibersor some other type of reinforcing fiber. The ply stack may bepre-impregnated with resin before being deposited on the forming surface224. In the alternative, a dry ply stack may be deposited on the formingsurface 224 and thereafter infused with resin. The resin-impregnated plystack is then cured under high temperature and pressure. Resulting isthe FRP part.

The FRP part may have structural inconsistencies such as delaminations,and foreign object debris. The ultrasonic testing reveals theseinconsistencies.

The apparatus 210 may further include an array controller 240 foroperating the transducer array 230. If the transducer array 230 isoperated in pulse echo (PE) ultrasonic mode, the controller 240 causesthe transducer array 230 to generate a sound beam that enters a frontsurface of the FRP part, hits the back wall, and is reflected backtowards the transducer array 230. The reflected signal returns to theorigination transducer, which measures the reflected acoustic energy. Ifa structural inconsistency is in the path of the sound beam, thestructural inconsistency will reflect the sound beam back to thetransducer array 230. A sound beam reflected off a structuralinconsistency will arrive at the transducer array 230 sooner than asound beam reflected off the back wall.

The transducer array 230 may have multiple time gates. A time gaterefers a window of analysis in time and amplitude. Gates are typicallyused to filter out data from wedges, front surfaces, etc. A time gatefor pulse echo is usually set to find reflections within the part, afterthe front surface of the FRP part.

The apparatus 210 may further include a second transducer array 235 onan opposite side of the FRP part. The controller 240 may operate bothtransducer arrays 230 and 235 in through-testing ultrasonic (TTU) mode.The controller 240 causes one of the transducer arrays to generate soundpulses that are transmitted through a front surface of the FRP part, andcontinues to the other one of the transducer arrays. The controller 240causes the other one of the transducer arrays to measure the transmittedacoustic energy transmitted through the back wall of the FRP part. ForTTU, the time gate is set across the entire FRP part.

The apparatus 210 may further include equipment such as a computer 250for processing the PE data and/or TTU data. For instance, the computer250 may convert the PE data and/or TTU data into a data representation(e.g., a C-scan) that identifies any structural inconsistencies in theFRP part.

The apparatus 210 may be used in the aircraft industry to validate thehealth (e.g., integrity and fitness) of large aircraft parts. Theapparatus 210 may perform ultrasonic inspection of a large FRP partwithout having to transfer the FRP part to a separate inspectionstation. Moreover, the apparatus 210 may perform the ultrasonicinspection without a robotic multi-axis scanning system scanning atransducer array over the FRP part. Ultrasonic testing with theapparatus 210 is less capital intensive, less labor expensive, andfaster to perform.

The apparatus 210 also eliminates need to determine position of thetransducer array 230 along the cured part. Consider conventionalultrasonic inspection that includes scanning a transducer array along anFRP part, and using an encoder to record position of the transducerarray as it is being scanned. The apparatus 210 eliminates the need forthe encoder, and it eliminates the need to correlate the PE data withthe position, since the flexible ultrasonic transducer array 230 isfixed relative to the FRP part during inspection.

The following paragraphs will describe different configurations of theapparatus 210 and different methods of performing ultrasonic testing.

Reference is made to FIG. 3 , which illustrates a first method of usinga forming tool 220 and a flexible transducer array 230 to fabricate anFRP part. The forming tool 220 of FIG. 3 has a forming surface 224 witha compound curvature.

At steps 3A and 3B, the flexible transducer array 230 is placed on theforming surface 224 and secured to the forming surface 224. That is, thetransducer array 230 is placed on the “tool side.” The transducer array230 conforms to the forming surface 224 and is in direct contact withthe forming surface 224.

Also at step 3B, a ply stack 310 is placed on the transducer array 230,and conforms to the compound curvature of the forming surface 224. Theply stack 310 may be pre-impregnated with resin prior to being placed onthe forming surface 224.

A parting layer (not shown) may be placed between the transducer array230 and the ply stack 310. The parting layer will facilitate separatingthe transducer array 230 from a cured part.

If a smooth finish for the part is desired, a caul may be placed betweenthe ply stack 310 and the transducer array 230. In the alternative, thetransducer array 230 may be encapsulated in a material (e.g., rubber orsilicone) that functions as a caul.

At step 3C, the ply stack 310 is bagged with a vacuum bag 320. Thetransducer array 230 is located underneath the vacuum bag 320.

At step 3D, the forming tool 220 is placed in an autoclave 330, whereinthe ply stack 310 is exposed to curing temperature and pressure toproduce an FRP part 340. Because the transducer array 230 is alsounderneath the vacuum bag 320 during curing, it too is exposed to thecuring temperature and pressure.

At step 3E, the forming tool 220 is removed from the autoclave 330, andultrasonic inspection of the FRP part 340 is performed. The transducerarray 230 is already acoustically coupled to the FRP part 340. In someinstances, the parting layer, caul, or encapsulation material mayprovide a coupling medium. In other instances, air coupling may beutilized. The air coupling may be utilized for lower resolution, lowerfrequency inspection. The transducer array 230 is connected to acontroller 240, which operates the transducer array 230 in pulse echomode to generate PE data. A computer 250 processes the PE data todetermine structural health of the FRP part 340. The inspection may beperformed before or after the vacuum bag 320 has been removed from thecured part 340. After the cured part 340 has been inspected, it isseparated from the transducer array 230 and moved off the forming tool220.

Certain operations may be performed on the FRP part 340 after it isremoved from the autoclave 330, but prior to ultrasonic inspection. Forexample, the FRP part 340 may be machined prior to ultrasonicinspection.

Reference is made to FIG. 4 , which illustrates a second method of usinga forming tool 220 and a flexible transducer array 230 to fabricate anFRP part. The second method is a variation of the first method in thatinspection is performed during curing instead of after curing.

Steps 4A, 4B and 4C are performed in the same manner as steps 3A, 3B and3C. That is, a transducer array 230 is placed on the forming surface 224of a forming tool 220, a ply stack 410 is placed on the transducer array230, and the ply stack 410 is bagged with a vacuum bag 420.

At step 4D, the forming tool 220 is placed in an autoclave 430, whereinthe ply stack 410 is exposed to curing temperature and pressure. Whilethe ply stack 410 is being cured, the controller 240 and computer 250obtain and process pulse echo data from the transducer array 230.

The ply stack 410 may be cured according to a profile. Certainparameters of the profile may be changed in response to the PE dataobtained during the curing. Parameters such as temperature and pressuremay be adjusted according to thickness (time-of-flight) or signalattenuation information. These parameters may be adjusted on the fly, orthey may be used to adjust the profile for curing future parts.

In addition, the PE data obtained during curing may be used to changetool and caul design. If the PE data identifies locations where porosityis forming, caul sheets may be adjusted to increase pressure locally.

The PE data may be used to terminate the curing prematurely. Forinstance, if the PE data reveals that foreign material is present early,the curing may be aborted. If the PE data reveals that the part will notpass inspection, the curing may be aborted.

The curing may be controlled by an independent curing controller 260.The computer 250 may analyze the pulse echo data and communicate theresults to the curing controller 260, or the computer 250 may send thePE data to the curing controller 260, which then analyzes the PE data.

Reference is made to FIG. 5 , which illustrates a third method of usinga forming tool 220 and the flexible transducer array 230 to fabricate anFRP part. At steps 5A and 5B, a ply stack 510 is placed on a formingsurface 224 of the forming tool 220. At step 5C, the transducer array230 is placed on the ply stack 510. That is, the transducer array 230 isplaced on the “bag side” of the ply stack 510.

At step 5D, the ply stack 510 is bagged with a vacuum bag 520, and theforming tool 220 is placed within an autoclave 530. While the ply stack510 is being cured or after cool-down, the controller 240 and thecomputer 250 may obtain and process PE data from the transducer array230. Step 5E may be performed in addition, or in the alternative, tostep 5D. At step 5E, the PE data may be obtained and processed after theforming tool 220 has been removed from the autoclave 530.

Reference is made to FIG. 6 , which illustrates a fourth method of usinga forming tool 220 and first and second flexible transducer arrays 230and 235 to fabricate an FRP part. At step 6A, the first transducer array230 is placed on the forming surface 224 of the forming tool 220. Atstep 6B, a ply stack 610 is placed on the first transducer array 230. Atstep 6C, the ply stack 610 is bagged with a vacuum bag 620.

At step 6D, the second transducer 235 is placed on the vacuum bag 620,over the ply stack 610. The vacuum bag 620 will provide acousticcoupling for the second transducer array 235.

At step 6E, the bagged ply stack 610 and the transducer arrays 230 and235 are placed within an autoclave 630. While the ply stack 610 is beingcured or after cool-down, the controller 240 and computer 250 obtain andprocess TTU data from the transducer arrays 230 and 235. At step 6F, Inaddition, or in the alternative, the TTU data may be obtained andprocessed after the forming tool 220 has been removed from the autoclave630. In addition to obtaining through transmission data from both arrays230 and 235, one of the arrays 230 or 235 may be used to obtain PE data.

Reference is made to FIG. 7 , which illustrates a mold 220 for forming acomposite part. The part may be made formed from a material such asplastic, rubber, metal, fiber reinforced plastic, ceramic, or acombination thereof. Examples of the mold 220 include an injection mold,resin transfer mold, and a press mold.

The mold 220 may include first and second halves 710 and 720. First andsecond flexible ultrasonic transducer arrays 230 and 235 are located onforming surfaces of the first and second halves 710 and 720. PE dataand/or TTU data may be collected while the part is still in the mold220. PE data and/or TTU data may be obtained after initial shaping orinjection/resin transfer, and during curing.

FIG. 8 also shows a mold 220 including first and second halves 810 and820. Transducer arrays 230 and 235 are located on outer surfaces of themold halves 810 and 820 instead of the forming surfaces. Part mark-offis avoided by placing the transducer arrays 230 and 235 on the outersurfaces of the mold halves 810 and 820.

If resin infusion or resin transfer molding is performed, the computer250 (not shown in FIGS. 7 and 8 ) may use the TTU data to track a liquidresin front moving through the ply stack or mold. The resin flowing intothe ply stack or mold creates a coupled path for the ultrasound (stresswaves) to travel from the sending transducer array to the receivingtransducer array. A negligible level of ultrasound travels across thedry material because the impedance mismatch between air and drymaterial, and the transducer array or mold material is very high. Theresin provides a good ultrasound path, which results in a higher signalat the receiving transducer array. By tracking the liquid resin front,complete wetting may be ensured, and void movement may be tracked andvoids eliminated.

The methods described above use a forming tool for fabricating a newpart. However, a method herein is not so limited. For example, theforming tool may be used to apply a repair patch to a damaged part.

Reference is made to FIG. 9 , which illustrates a forming tool includinga heat blanket 910. The heat blanket 910 may include a set of insulatedwires sandwiched inside a medium that distributes heat and that issurrounded by rubber. The wires heat up when subjected to an electriccurrent, and the medium generates an area of (mostly) uniform heating.

A flexible ultrasonic transducer array 230 is secured to a surface ofthe heat blanket 910, or it is embedded with the heat blanket 910.

To repair a damaged area of a composite structure 920, the damaged areais removed, and a patch (not shown) of resin-impregnated composite isplaced within the removed area. The blanket 910 is placed over thepatch. The blanket 910 is heated to cure the patch. During curing and/orafter curing, PE data is collected from the transducer array 230. The PEdata is processed to identify any structural inconsistencies in thepatch during and/or after curing.

In the methods described above, the cured or molded part may beseparated from the forming tool or mold. However, a method herein is notso limited. For instance, the transducer array 230 may be co-cured orco-bonded with a composite part during curing. After curing, thetransducer array 230 is separated from the forming tool 220. Thetransducer array 230 is embedded in the part.

Reference is made to FIG. 10 , which illustrates a composite part 1010with an embedded flexible transducer array 230. An advantage ofembedding the transducer array 230 in the part 1010 is that it allowsin-situ inspection of the part 1010. As some examples, in-situinspection may be used to monitor damage growth in mechanical testing orto provide structural health monitoring (SHM) in “hot spots” or limitedaccess areas. The embedded array 230 may replace individual transducerstypically used for in-situ NDI, thereby significantly increasingsensitivity to damage and improving the tracking of growth of structuralinconsistencies. Individual transducers inspect locally for growth. Theyare typically spaced apart, so growth in between the individualtransducers may be missed. A flexible transducer array having crossingelectrodes may be designed to essentially track growth at any point onthe part 1010.

Although not so limited, the part 1010 is shown with a rounded 3-Dcorner. Sharp corner radii are sometimes more difficult to inspect. Theflexible ultrasonic transducer array simplifies the inspection of sharpcorner radii.

The apparatus and methods described above utilize an ultrasonictransducer array that is flexible. In some instances, however, a rigidultrasonic transducer array may be used. As a first example, a rigidarray may be pre-molded to fit on the forming surface of a forming tool.As a second example, the forming surface and the transducer array may beplanar.

What is claimed is:
 1. A method of fabricating a part from an uncured,fiber reinforced plastic ply stack, the method comprising: placing theuncured, fiber reinforced plastic ply stack on a forming tool having aforming surface, a first ultrasonic transducer array provided on theforming surface and having an array surface configured to receive theuncured, fiber reinforced plastic ply stack, the first transducer arraycomprises a mat, a layer of piezoelectric material on each of opposingsides of the mat, and a plurality of electrodes on each layer ofpiezoelectric material, the plurality of electrodes are arranged suchthat each electrode on one side of the mat overlaps a portion of anelectrode on the opposite side of the mat, the overlapping electrodesare configured to enable ultrasonic inspection of all points on thefiber reinforced plastic ply stack; heating the forming surface of theforming tool to a curing temperature sufficient to cure the fiberreinforced plastic ply stack; and during or after heating, obtaining andprocessing ultrasonic data from the first ultrasonic transducer arraywith the fiber reinforced plastic ply stack still on the firstultrasonic transducer array.
 2. The method of claim 1, furthercomprising bagging the uncured, fiber reinforced plastic ply stack witha vacuum bag, whereby the first ultrasonic transducer array is withinthe vacuum bag, and curing the uncured, fiber reinforced plastic plystack while the first ultrasonic transducer array is underneath thevacuum bag.
 3. The method of claim 1, further comprising obtaining atleast one of pulse echo data and through transmission data from thefirst ultrasonic transducer array while the uncured, fiber reinforcedplastic ply stack is being cured.
 4. The method of claim 3, furthercomprising using the pulse echo data to control the heating of theforming surface of the forming tool.
 5. The method of claim 3, in whichheating the forming surface of the forming tool comprises heatingaccording to a profile.
 6. The method of claim 5, in which parameters ofthe profile are modified in response to the pulse echo data obtainedduring the heating.
 7. The method of claim 1, in which a controller andcomputer are operatively coupled to the first ultrasonic transducerarray, the controller and computer configured to obtain and process theultrasonic data from the first ultrasonic transducer array.
 8. Themethod of claim 7, in which a heater is operatively coupled to theforming surface of the forming tool, and in which the controller andcomputer are operatively coupled to the heater and further configured tooperate the heater to heat the forming surface of the forming tool tothe curing temperature.
 9. The method of claim 7, in which thecontroller and computer are configured for obtaining and processingthrough transmission ultrasonic data from the first ultrasonictransducer array.
 10. The method of claim 9, wherein: placing theuncured, fiber reinforced plastic ply stack on the forming toolcomprises: placing a dry ply stack on the forming surface, andthereafter infusing the dry ply stack with liquid resin; and whereinobtaining and processing through transmission ultrasonic data from thefirst ultrasonic transducer array comprises: tracking, using the throughtransmission ultrasonic data, a liquid resin front moving through thefiber reinforced plastic ply stack when infusing with the liquid resin.11. The method of claim 1, in which the forming surface comprises acurved forming surface, and in which the first ultrasonic transducerarray comprises a flexible array that conforms to the curved formingsurface.
 12. The method of claim 1, in which the first ultrasonictransducer array is in direct contact with the forming surface andconforms to the forming surface.
 13. The method of claim 1, in which:the first ultrasonic transducer array contacts and conforms to theforming surface; the fiber reinforced plastic ply stack is disposed onthe first ultrasonic transducer array; and a second ultrasonictransducer array is disposed on the fiber reinforced plastic ply stack.14. The method of claim 1, in which: the forming tool comprises a firstforming tool of a mold; a second forming tool of the mold is provided;and the first and second forming tools are configured to form the part.15. The method of claim 1, in which the forming tool comprises a heatblanket, and in which the first ultrasonic transducer array is on asurface of the heat blanket.
 16. A method of fabricating a part from anuncured, fiber reinforced plastic ply stack, the method comprising:placing the uncured, fiber reinforced plastic ply stack on a formingtool having a curved forming surface, a heat blanket provided on thecurved forming surface, a first ultrasonic transducer array provided onthe heat blanket, the first ultrasonic transducer array having an arraysurface configured to receive the uncured, fiber reinforced plastic plystack; using the heat blanket to heat the curved forming surface of theforming tool to a curing temperature sufficient to cure the fiberreinforced plastic ply stack; and during or after heating, using acontroller and a computer operatively coupled to the first ultrasonictransducer array to obtain and process ultrasonic data from the firstultrasonic transducer array with the fiber reinforced plastic ply stackstill on the first ultrasonic transducer array.
 17. The method of claim16, in which the controller and computer are operatively coupled to theheat blanket, the controller and computer being programmed to heat thecurved forming surface according to a profile, and modify parameters ofthe profile in response to the ultrasonic data from the first ultrasonictransducer array.
 18. A method of fabricating a part from an uncured,fiber reinforced plastic ply stack, the method comprising: providing aforming tool having a forming surface and a first ultrasonic transducerarray disposed on the forming surface and having an array surfaceconfigured to receive the uncured, fiber reinforced plastic ply stack,the first transducer array comprises a mat, a layer of piezoelectricmaterial on each of opposing sides of the mat, and a plurality ofelectrodes on each layer of piezoelectric material, the plurality ofelectrodes are arranged such that each electrode on one side of the matoverlaps a portion of an electrode on the opposite side of the mat, theoverlapping electrodes are configured to enable ultrasonic inspection ofall points on the fiber reinforced plastic ply stack; providing a heaterconfigured to heat the forming surface of the forming tool; providing acontroller and a computer operatively coupled to the first ultrasonictransducer array; placing the uncured, fiber reinforced plastic plystack on the forming surface; using the heater to heat the formingsurface of the forming tool to a curing temperature sufficient to curethe fiber reinforced plastic ply stack; and during or after heating,using the controller and a computer to obtain and process ultrasonicdata from the first ultrasonic transducer array with the fiberreinforced plastic ply stack still on the first ultrasonic transducerarray.
 19. The method of claim 18, in which the controller and computerare operatively coupled to the heater, the controller and computer beingprogrammed to heat the forming surface according to a profile, andmodify parameters of the profile in response to the ultrasonic data fromthe first ultrasonic transducer array.
 20. The method of claim 18,further comprising bagging the uncured, fiber reinforced plastic plystack with a vacuum bag, whereby the first ultrasonic transducer arrayis within the vacuum bag, and curing the uncured, fiber reinforcedplastic ply stack while the first ultrasonic transducer array isunderneath the vacuum bag.